Method for producing laundry products

ABSTRACT

A method for producing a laundry product comprising generally spherical beads formed from particles of soap, synthetic detergent, or the like. In the method of this invention, the particles are formed into an annular fluidized bed of particles and gas in a rotatable chamber as a result of relative high speed rotation of the chamber and continuous introduction of gas into the rotating chamber. Periodically the particles are tumbled in the chamber by abruptly reducing the rotational speed of the chamber. The particles may be treated in the chamber by the introduction of fluids onto the particles in the rotating chamber. The generally spherical beads of soap, synthetic detergent or the like produced by the method of this invention are relatively dense, have a relatively low moisture content and may include one or more outer layers or coatings of solidified treating fluid, with each bead containing substantially the same materials and proportion of materials as are in the other beads.

United States Patent [191 Marshall [451 Sept. 25, 1973 METHOD FOR PRODUCING LAUNDRY PRODUCTS Donald E. Marshall, 4904 Sunnyside Rd., Edina, Minn. 55424 [22] Filed: Mar. 17, 1971 [21] Appl. No.: 125,319

Related U.S. Application Data [62] Division of Ser. No. 773,585, Nov. 5, 1968, Pat. No.

[76] Inventor:

Primary Examiner-Robert F. White Assistant Examiner--.l. R. Hall Attorney-Frederick E. Lange, William C. Babcock and Eugene L. Johnson 57 ABSTRACT A method for producing a laundry product comprising generally spherical beads formed from particles of soap, synthetic detergent, or the like. In the method of this invention, the particles are formed into an annular fluidized bed of particles and gas in a rotatable chamber as a result of relative high speed rotation of the chamber and continuous introduction of gas into the rotating chamber. Periodically the particles are tumbled in the chamber by abruptly reducing the rotational speed of the chamber. The particles may be treated in the chamber by the introduction of fluids onto the particles in the rotating chamber.

The generally spherical beads of soap, synthetic detergent or the like produced by the method of this invention are relatively dense, have a relatively low moisture content and may include one or more outer layers or coatings of solidified treating fluid, with each bead containing substantially the same materials and proportion of materials as are in the other beads.

7 Claims, 9 Drawing Figures PATENIED E Z 3.761.549

' sum 2 or 3 INVENTOR. ALD E MAEJZAU METHOD FOR PRODUCING LAUNDRY PRODUCTS CROSS-REFERENCE TO RELATED APPLICATION This application is a division of the parent copending application entitled Machine and Method for Producing Laundry Products, Ser. No. 773,585, filed Nov. 5, 1968, now US. Pat. No. 3,588,950.

BACKGROUND OF THE INVENTION This invention relates to a method for producing laundry products, and more particularly, to a method for producing a novel dense, low moisture, generally spherical bead of a laundry product such as soap or a synthetic detergent. The beads of the present invention may consist of. nucleus of one type of laundry material and an outer continuous layer(s) of other laundry materials.

In the past, conventional laundry products, such as the particles of soap and synthetic detergents, have been generally made in conventional spray towers. These particles have had a generally irregular shape, have been porous and have had a moisture content of above ten percent by weight. Also in the past, spherical bead products have been shaped in conventional pill rolling machines in which the products to be shaped are placed in the large drums or chambers and rotated therein at a relatively low rotational speed so that the products or particles are continuously tumbled in the drum.

In contrast, in the'method of this invention the particles to be shaped and/or treated are rotated at a relatively high speed so that the particles form an annular bed or layer about the central longitudinal'axis of the chamber in which they are rotated and adjacent to the side wall of the chamber. Gas under pressure is continuously introduced into the rotating chamber so as to fluidize the annular bed of particles so that the particles in the bed are in a constant state of agitated motion whereby the particles are continuously contacting or striking adjacent particles and the walls of the chamber. Periodically the rotational speed of the chamber is reduced from said relatively high speed to an interm diate speed. The intermediate speed is selected so that the centrifugal force acting on the particles is now less than the gravitational force acting thereon whereby the particles in the upper segment of the chamber fall away from the side wall of the chamber and are cast down upon the lower segment of the chamber and the particles therein. This tumbling compacts and hardens the surface of the particles andassists in shaping the particles.

The rotating chamber in which the particles are rotated is positioned in a shroud and gas is introduced into the shroud from a motor driven blower. The gas in the shroud may be heated prior to its introduction into the rotating chamber and after the gas passes through the annular bed of fluidized particles and gas in the chamber, the gas is exhausted from the chamber through an aperture located adjacent the central longitubes interconnecting the manifold with the chamber. The manifold is connected with a source of gas under pressure such as a rotary compressor.

Therefore, it is the primary object of the present invention to provide a method for producing a laundry product comprising dense, generally spherical beads which may have a nucleus of one material and an outer layer of other materials.

Another object of the present invention is to provide an improved method of shaping and treating particles of soap, synthetic detergent and the like wherein the particles are rotated in a chamber at a relatively high speed so that the particles form and maintain a generally annular bed about the rotational axis of the chamber; wherein the particles are fluidized in the annular bed by the continuous introduction of the gas under pressure into the bed; and wherein periodically the fluidized particles are tumbled in the rotating chamber. A related object of the present invention is to provide an improved method of the type described wherein the particles are tumbled in the chamber by reducing the rotational speed of the chamber from the relatively high speed ,to an intermediate speed whereby a large portion ofthe fluidized particles fall away from the side tudinal axis of the chamber. A portion of this exhaust gas maybe recirculated back into the interior of the shroud after passing through a filter. In another embodiment of the machine of the present invention gas is introduced into the rotating chamber by means of a central manifold mounted on one of the end walls of the chamber and a plurality of radial and transverse wall of the chamber and are cast down on a lower segment of the rotating chamber; and wherein the annular, fluidized bed of particles and gas is reformed again by quickly returning the chamber to therelatively high speed.

These and other objects of the present invention will become apparent from the accompanying specification, claims and drawings.

DESCRIPTION OF THE DRAWINGS FIG. II is a vertical cross-sectional view of a machine used to preform the methodof the present invention.

FIG. 2 is a partial vertical cross-sectional view taken along lines 2 2 in FIG. 1.

FIG. 3 is a perspective view of a fan and plenum chamber utilized in the machine shown in FIG. 1.

FIG. 4 is a vertical cross-sectional view taken along lines 4 4 in FIG. 1 and showing the annular layer of fluidized particles and gas formed in the rotating chamber.

FIG. 5 is a vertical cross-sectional view taken along lines 4 4 in FIG. I and showing the particles in the rotating chamber being tumbled during a period in which the chamber is rotating at an intermediate speed.

FIG. 6 is a vertical cross-sectional view taken along lines 4 4 in FIG. 1 and showing the trough in position for removing beads from the rotating chamber.

FIG. 7 is a partial, vertical cross-sectional view of a machine which has a modified means for introducing gas under pressure into the rotating chamber, and which may be employed in carrying out the method of the present invention.

FIG. 8 is a partial, vertical cross-sectional view taken along lines 8 8 in FIG. 7.

FIG. 9 is a cross-sectional view of a detergent particle with a layer of coating material thereon.

DESCRIPTION OF THE PREFERRED EMBODIMENT A, machine suitable for carrying out the method of the present' invention is shown generally at M. The machine 11 includes a sheet metal shroud 12 which is secured to the floor 13 by a plurality of conventional fasteners, not shownv The shroud 12 is constructed so as to prevent the leakage of gas from the interior thereof during the operation of the machine and includes a front wall 14, a top wall 15, a rear wall 16 and a bottom wall 17 which slopes forwardly, or to the left as shown in FIG. 1. A hinged clean-out door 18 is located in the front wall 14, near the floor, and permits access to the interior of the shroud for the purpose of removing dirt, dust and the like therefrom.

The central portion 19 of the front wall 14 of the shroud 12 is flared outwardly, or in other words, projects to the left as shown in FIG. 1. A central aperture 21 is formed in the portion 19, and a tube 22 is secured within the aperture 21 so that approximately one-third of the tube projects forwardly from the front wall 14, and so that the right end 23 of the tube 22 extends within the shroud. A conventional, annular gas filter 24 is positioned within the tube 22 and is designed to permit gas to pass radially, with respect to the central longitudinal axis of the tube, therethrough. The righthand portion of the tube 22, i.e., the two-thirds portion thereof positioned within the shroud, is perforated so that gas may pass from the interior of the tube into the interior of the shroud 12. A removable cover 25 tightly closes the projecting left end of the tube 22 so as to prevent leakage of gas therefrom.

A gas exhaust conduit 26 is positioned in communication with the interior of the tube 22 so as to permit gas to be exhausted from the tube and thus from the shroud. A conventional gas filter 27 is positioned in the conduit 26 and is utilized to filter and remove any dirt, dust or like materials entrained in the exhausted gas.

A generally cylindrical, rotatable chamber 28 is mounted within the interior of the shroud 12 on the flanged end 29 of a rotatable shaft 31 and is arranged so that the central longitudinal axis of the chamber 28, shaft 31 and the tube 22 are coaxial. The shaft 31 projects into the shroud through a conventionally sealed aperture 32 mounted in the rear wall 16 of the shroud. The dimensions of the interior of the shroud are such that when the chamber 28 is positioned within the shroud, as shown in FIG. 1, there is ample clearance between the chamber and the walls of the shroud whereby the chamber may be rotated within the shroud at relatively high speeds without danger of contact between the rotating chamber and the walls of the shroud.

Adjacent to the rear wall 16, the shaft 31 is journaled in conventional bearings 33 carried by a pedestal support 34 which is mounted on the floor 13. The other end 35 of the shaft 31 is journaled in a conventional bearing 36 which is carried by a second pedestal support 37 also mounted on the floor 13. A plurality of sheaves or pulleys 38 are mounted on the shaft 23 adjacent the bearing 36. The sheaves 38 are adapted to be driven by the V-belts 39.

A conventional two-speed electric motor 40 is mounted on a support 41 which in turn is positioned on the floor 13. The motor 41 is of the type which will permit the polarity of its windings to be reversed by changing the connections of the motor windings so that when the connections are reversed, the motor will act as a brake.

The output shaft 42 of the motor has a pair of sheaves or pulleys 43 mounted thereon. These sheaves 43 receive the V-belts 39 so that the motor 40 is connected with and thus selectively drives or brakes the shaft 31 and the chamber 28.

A conventional air or gas blower 44 is also driven by the motor 40. As shown in FIG. 1 the inlet 45 of the blower 44 communicates directly with the atmosphere, although, of course, the inlet 45 could be connected with another source of gas or air. The outlet of the blower 44 is connected by a conduit 46 with the interior of the shroud 12. More particularly, the conduit 46 extends from the blower 44 to an inlet 47 formed in the bottom wall 17 of the shroud 12.

As shown schematically in FIG. 1, a conventional gas heating unit, shown schematically at 48, is positioned adjacent the inlet 47. The purpose of the unit 48 is to heat the gas being introduced into the shroud from the blower so that the high temperature gas may be used, during at least a portion of the cycle of operation of the machine 11, to heat the particles being shaped and treated within the chamber 28.

The chamber 28 includes generally circular front and back end walls 49 and 51 and a continuous, annular side or outer wall 52. The side wall is formed so that its central portion 53 is spaced radially inwardly, relative to the end portions thereof, and so that the side wall is symmetrical about a plane passing through the center of the side wall 52 and perpendicular to the central longitudinal axis of the chamber.

An aperture 54 is formed in the front end wall 49, with the diameter of the aperture 54 being substantially equal to the diameter of the tube 22. The chamber 28 is positioned within the shroud 12 so that the center of the aperture 54 is aligned with the central longitudinal axis of the tube 22. The open, right end 23 of the tube 22 and the peripheral edge of the aperture 54 may be formed, as shown, so that a conventional running gas seal 55 is provided therebetween. This arrangement of the tube and aperture 54 permits gas to flow freely from the interior of the chamber and the interior of the tube. Moreover, as noted above, gas may pass from the interior of the tube through the filter 24, and the perforations in the tube 22 and into the interior of the shroud A loading conduit 56 is mounted in the tube 22 and is used for introducing the soap or synthetic detergent particles 57 to be shaped and treated into the interior of the chamber 28. The conduit 56 is positioned within the tube 22 so that one end 58 thereof extends through the cover 25. The other end 59 of the conduit 56 is supported adjacent to, but spaced from, the periphery of the aperture 54. The end 58 of the conduit 56 is positioned higher, relative to the ground 13, than the other end 59 so that the particles may be gravity-fed into the interior of the chamber 28.

An unloading conduit 61 is also mounted in the tube 22 and is used to remove the beads, i.e., the particles which have been shaped and treated in the chamber, from the chamber. Like conduit 56, conduit 61 is positioned so that one end 62 thereof extends through the cover 25 and the other end 63 thereof is supported adjacent to, but spaced from, the periphery of the aperture 54. The end 63 of conduit 61 is higher, relative to the ground 13, than the end 62 so that the heads will move through the conduit 61 from the end 63 to the end 62 by gravity.

A trough 64 has its open end 65 supported by the bracket 66 and extends across the chamber 28, with the longitudinal axis of the trough being generally parallel with, but spaced from, the central longitudinal axis of the chamber. The end 65 of the trough is positioned immediately above the other end 63 of the conduit 61, and the end 67 of the trough is positioned adjacent to, but not in contact with, the rear wall 51 of the chamber 28. The trough 64 is generally U-shaped in crosssection, i.e., generally U-shaped in a plane perpendicular to its central longitudinal axis.

A conventional electric motor 68 is also mounted on the bracket 66, and connected with the end 65 of the trough 64 so that the trough 64 may be rotated by the motor about the central longitudinal axis of the trough from a first position, such as shown in FIG. 4, where the open side of the trough faces the upper segment of the chamber 28 to a second position, 180 from the first position, where the open side of the trough faces the lower segment of the chamber, such as shown in FIG. 6.

A conventional electrical vibrator unit, shown schematically at 69, is connected with the trough 64 and is utilized to vibrate the trough 64 so as to assure that the beads caught therein, as hereinafter described, are moved along the trough from the end 67 toward the end 65. As noted above, the trough 64 is positioned so that its end 65 is positioned above and adjacent to the end 63 of the conduit 61. When thebeads caught in the trough are moved toward the open end 65, as a result of the operation of the unit 69, they fall into the conduit 61, and thus are removed from the machine 11. The vibrator unit 69 may be of the type manufactured and sold by the Syntron Division of F.M.C. Corporation, Homer City, Pa. 1

A conventional spray nozzle 71 is positioned within the chamber 28, adjacent the center thereof, and may be used to spray fluids onto the particles in the lower segment of the chamber. The nozzle 71 is connected with and supported by a pipe 72 which extends from the chamber 28 through the tube 22 and cover 25. The pipe may be connected to one or more sources of pressurized fluid, not shown. A conventional pipe coupling 73 is used in the pipe 72 to facilitate removal of the cover 25. A conventional, electrically controlled valve 74 is positioned in the pipe 72 and controls flow through the pipe.

A plurality of relatively small diameter holes 75 are drilled in the front and rear walls 49 and 51 of the chamber 28 adjacent to, but spaced radially inwardly from, the side or outer wall 52. The holes 75 are equispaced about a circle having as its center the central longitudinal axis of the chamber. The holes are arranged with respect to the side wall 52 so that when the gas under pressure is introduced into the chamber 28 through the holes, as hereinafter described, a generally annular fluidized bed or layer of particles and gas is formed in the chamber 28, during rotation of the chamber.

A unique fan-plenum chamber assembly 76 is utilized to force gas, under pressure, into the interior-of the chamber 28 through the holes 75. This assembly 76, shown best in FIGS. 2 and 3, consists of a plurality of curved fan blades 77 and plenum chambers 78 which are mounted on the exterior faces 79 of both the front and rear walls 49 and 51. Since the assemblies 76 mounted on the walls 49 and 51 are identical, only the assembly 76 on the wall 51 will be described in detail.

As shown in FIGS. 2 and 3, the plenum chambers 78 are wider at their radial outer ends, i.e., the ends adjacent to the periphery of the wall 51, than at their radial inner ends, i.e., the ends adjacent to the center of the wall 51. The longitudinal center lines of the chambers 78 are disposed at an acute angle, e.g., 20 30, with respect to a radius of the wall 511, with the inner ends of each chamber 78 leading the outer end thereof in the direction of rotation of the chamber 28, this direction of rotation being indicated by the arrow 81 in FIG. 2.

All the fan blades and plenum chambers are structurally and functionally identical and, as best shown in FIG. 3, each chamber 78 includes a top panel 82 spaced from and parallel with the exterior face 79 of the end wall 51 of the chamber 28. The outer radial edge of the top panel 82 overlies and is congruent with the underlying peripheral arc of the end wall 51 so that the top panel overlies a number of the holes 75. While in FIG. 3, the top panel 82 is shown overlying or covering three holes 75, the specific number of holes covered by a top panel 82 is not critical so long as proper fluidization is obtained in chamber 28.

A pair of side panels 83 extend between the exterior face 79 and the side edges of the top panel 82. As shown in FIG. 2, the side panels 83 converge together at their radially inner ends, i,e., the inner ends of the side panels are spaced closer together than the outer ends thereof, so that each chamber 78 has a generally frusto-conical shape. An outer end panel 84 extends between the exterior face 79, the outer edge of the top panel 82 and between the radially outer ends of the side panels 83 so as to completely close the radially outer end of the chamber 78, except, of course, for the holes 75 enclosed within the chamber 78. An inner end panel 85 extends between the radially inner ends of the side panels 83 and the face 79 ofvwall 51. An opening 86 is defined in the top of the chamber 78 between the radial inner end 87 of the top panel 82, the inner end panel 85 and the side panels 83.

The curved fan blade 77 projects beyond the plane of the top panel 82, is integrally formed with the trailing side panel 82, relative to the direction of rotation of the chamber 28, and extends along the side of the opening 86. The axial height of the blades 77, relative to the chamber '78, is determined by the gas capacity or volume of flow desired.

The fan blades 77 are utilized during rotation of the chamber 28 to forcibly direct the gas in the shroud 12 into the plenum chambers '78 and hence, under pressure, through the holes 75 into the chamber 28. The design of the plenum chambers 78, including the angular disposition of the plenum chambers 78, relative to a radius of the end wall 5l,'assists in forcing gas through the plenum chambers 78 and into the chamber 28 during rotation of the chamber in a manner similar to that of a conventional centrifugal blower or fan.

The operation of the motor 68, the vibrator unit 64, the motor 48, the unit 48 and the valve 74 is controlled by a conventional timing mechanism 88. The timing mechanism 88 employs an electric motor which sequentially operates a plurality of switches in a presesame reference numerals have been used to indicate common parts in machines 11 and 89.

Chamber 90 is structurally similar to chamber 28, except that its side wall 91 is straight, as distinguished from the curved side wall 52. For this reason, a further detailed description of the chamber 90 is not included herein.

Chamber 90 utilizes a manifold 92 and a plurality of radial and transverse pipes 93 and 94, respectively, to accomplish the same function as is accomplished by the fanplenum chamber assembly 76 used in connection with chamber 28. The manifold 92 is centrally mounted on the end wall 51 and interconnects the end 95 of the shaft 96 and the end wall 51 of the chamber 90. The shaft 96, supported and driven in a manner similar to shaft 31, is similar to shaft 31 except that the shaft 96 includes a central passage, not shown. The manifold 92 is connected with the outlet of a rotary compressor, shown schematically at 97, by means of a conduit 98 which, in turn, is in communication with the central passage in the shaft 96. The shaft 96 performs the dual function of supporting the chamber 90 for rotation as well as supplying gas to the manifold 92.

Each of the radial pipes 93 is connected at one end, through a metered orifice 101, with the manifold 92. As best shown in FIG. 8, the pipes 93 are equi-spaced around the circumference of the manifold 92, and extend radially outwardly, adjacent to the end wall 51, from the manifold so that the outer ends thereof project beyond the periphery of the chamber 90, i.e., just beyond the side wall 91. Each pipe 93 is connected at its radial outer end with an end of a transverse pipe 94 which extends axially, adjacent to the outer surface of and across the side wall 91. The other end of the transverse pipe 94 is closed.

Each of the transverse pipes 94 has a plurality of tubes 102 connected thereto which extend radially inwardly, relative to the central longitudinal axis of the chamber 90, through the side wall 91 of the chamber 90 into the interior of the chamber so that the open, inner ends of the tubes 102 project slightly beyond the inner surface of the side wall 91. As shown in FIGS. 7

and 8, the tubes 102 and the inner ends thereof are spaced closely together so that the pressurized gas emitted from the ends of the tubes 102 is capable of creating and maintaining a bed of fluidizing particles and gas in the chamber 90.

DESCRIPTION OF METHOD OF OPERATION As described above, the synthetic detergent or soap particles 57 which are to be shaped and/or treated in machine 11 are introduced into the rotating chamber 28 through the conduit 56. These particles may be the end product from a conventional spray tower utilized in the manufacture of irregularly shaped, conventional soap and detergent particles and may be conveyed directly from the bottom of the tower into the chamber 28 or from a hopper.

The rotational speed of the chamber 28 is selected so that during relatively high-speed rotation of the chamber, the particles will form and maintain a generally annular bed or layer adjacent to the side wall 52 of the chamber, as shown in FIG. 4. Moreover, because of the fan-plenum chamber assembly 76 mounted on the end walls 49 and 51 of the chamber, the gas in the interior of the shroud 12 is forced through the holes 75 formed in the end walls 49 and 51. The number and size of the fans 77 and plenum chambers 78 are correlated with the rotational speed of the chamber 28 so that the gas being forced into the rotating chamber through the holes is sufficient to form a completely fluidized bed of particles and gas. In this annular fluidized bed, the particles are in continuous agitated motion as the gas passes into and through the bed so that the particles continually strike and come into contact with each other and with the walls of the chamber 28 whereby the particles are shaped into compact, generally spherical beads. After passing through the bed, gas is exhausted from the chamber 28 through the aperture 54. A portion of the exhausted gas is then removed from the machine through conduit 26 and the remainder of the gas is recirculated back into the interior of the shroud 12 through the filter 24. This recirculated gas, of course, is again introduced into the chamber 28.

To assist in the shaping of the particles, the gas introduced into the shroud 12 may be heated by the heating unit 48 to a temperature whereby the heated gas causes the particles to become somewhat plasticized. In addition, the fluidization and heating of the particles reduces the moisture content of the particles far below that of the original particles and, for example, below 5 percent by weight. Thus, the moisture content of the particles and resulting beads of this invention is significantly less than that of conventional soap or detergent particles.

If it is desired to treat or coat the particles in the chamber 28, a treating or coating fluid may be introduced in the rotating chamber and sprayed onto the particles through the nozzle 71. The timing mechanism 88 controls the flow through the valve 74, and thus through the nozzle 71, and therefore, if desired, the introduction of the fluid may be regulated with respect to the rotation of the chamber.

Periodically, the timing mechanism 88 causes the windings of the motor 40 to be reversed so that the motor abruptly brakes the chamber 28, thus causing the speed of the chamber 28 to be reduced from the relatively high speed at which the particles form and maintain a generally annular bed to an intermediate speed setting for the two-speed motor 40. This intermediate speed may just be 5 or l0 percent less than the relatively high speed, but must be low enough so that the gravitational force acting on the particles overcomes the centrifugal force acting on the particles whereby the particles in the upper segment of the chamber fall away from the side wall 52 and are cast down upon the lower segment of the chamber and upon the particles in the bed in the lower segment of the chamber, as shown in FIG. 5. This causes additional compaction of the particles and hardens the outer surface of the particles. Moreover, during the time the speed of the chamber is below the relatively high speed, the particles are tumbled in the chamber and this also assists in shaping and hardening the particles. Almost immediately after the timing mechanism 88 has caused a reduction in the speed of the chamber 28, the timing mechanism causes the windings of the motor 40 to be switched back to their original position so that the motor again drives the chamber 28 at the relatively high speed.

A typical cycle operation for forming and maintaining tha annular bed in the chamber 28, abruptly braking or reducing the rotational speed of the chamber to the intermediate speed and returning the speed of the chamber back to the relatively high speed, may take from to seconds. Approximately one-half of this cycle may be utilized for forming and maintaining the particles in the annular bed, approximately one-quarter of the cycle may be utilized for reducing the speed of the chamber from the relatively high speed to the intermediate speed and the other one-quarter of the cycle may be utilized for tumbling the particles during the time the speed of the chamber is below the relatively high speed and for returning the rotational speed of the chamber from the intermediate speed to the relatively high speed or, of course, the periods of relatively high speed operation or intermediate speed operation may be made of much longer duration.

The operation of the machine b9 shown in FIG. 7 is identical to the foregoing description of the machine ll, except that the gas is introduced into the chamber 90 through the manifold 92 and a plurality of pipes 93 and 941. The gas may be heated, if desired, prior to its introduction into the manifold by a conventional heater, not shown, positioned in conduit 98. The operation of machine 89 does include the recirculationof gas.

After the particles 57 have been shaped and treated in the chamber a sufficient length of time, i.e., for a sufficient number of cycles of operation, the resulting beads appear generally as shown in FIG. 9, with the reference numerals 1% indicating the portion of the bead which was introduced into the chamber and the reference numeral 103 indicating a layer of coating material which was added to the portion 1104 during the treatment of the particles in the chamber.

As noted above, the trough 64 is positioned, as shown in FIGS. 4 and 5, so that its open side is directed toward the lower segment of the chamber during the time the particles are being shaped and/or treated in the chamber 28. when the desired number of cycles of operation have been completed, however, the timing mechanism 88 actuates the electric motor 68 and the motor rotates the trough 180 from the position shown in FIGS. 4 and 5 to the position shown in FIG. 6 wherein the open side of the trough is directed toward the upper segment of the chamber. Thus, when the chamber 28 is next abruptly braked from the relatively high speed to the intermediate speed, a portion of the beads falling away from the upper segment of the chamber land in or are caught in the trough 64. When the trough is in the position shown in FIG. 6, the timing mechanism 88 also causes the vibrator unit 69 to operate so that the beads caught in the trough 64 are moved toward the left, as shown in FIG. I, are deposited in the conduit 61 and are thereby removed from the machine. As the operation of the machine is repeated, the chamber 28 is completely emptied of beads.

The beads produced by the methods described herein have a density of greater than 50 pounds per cubic foot and a generally specific gravity for the bead of approximately nine-tenths, with a moisture content of below five percent by weight. These beads are designed for use in automatic washers which are equipped with mechanical or hydraulic dissolvers, and in which the clothes or fabrics to be cleaned are not introduced into the washer until after the beads have been thoroughly dissolved and diluted. 7

The composition or makeup of the beads produced by the method of this invention may vary. For example, a bead produced by the method of this invention may have a nucleus of potash soap protected by a continuous, outer layer of soda soap. The soda soap layer, of course, would be introduced through the nozzle 71 while the nucleus of potash soap would be introduced into the chamber through the conduit 56. The advantage of using a bead of this type is that the active ingredients of soda soap cost approximately one-half the cost of the active ingredients of synthetic detergents. The outer layer of soda soap is to prevent the caking or absorbtion of moisture by the more active potash soap nucleus.

Another type of bead which could be produced is a bead having a mild caustic detergent outer layer with a nucleus ofa strong caustic detergent so that when the bead is dissolvedto a concentration of three-tenths percent in soft water, i.e., water having below 50 parts per million of hardness components, the solution of clothes and water would have a pH of 8.5 10. A similar type of bead could be used in hard water, i.e., water having hardness components of between 50 and 200 parts per million, so that when the bead is dissolved, to a concentration of five-tenths percent, the solution of clothes and water would have a pH of 9.5 12.0. The advantage of using the milder outer caustic layer is that it would facilitate the handling of the beads and permit, for the first time, a strong caustic solution, such as now used in the commercial laundries, to be safely used in the home.

Likewise, the beads produced by the method of this invention could also have a nucleus of a bluing material, a fluorescent bluing dye, a clothes bleaching chemical or a rinse promoting chemical with the outer layer being a detergent product. Still another example of such beadswould be a bead having an outer layer of water softening chemicals, such as metasilicate, and a nucleus of potash soap.

The variations and different combinations of nucleus and outer layer materials which may be utilized in the method of the present invention, of course, are not lim ited to the examples given above; and it should be understood that the methods of this invention provide an economical and efficient way of producing laundry products in a dense bead form in which two or more products can be combined so that each bead contains the same chemicals and same proportion of chemicals as all other beads, within, of course,'normal manufacturing tolerances.

Thus, it should be apparent from the foregoing that the invention described herein provides a unique and novel method for shaping and treating laundry products which will permit those products to be economically attractively soldboth to the home and commercial laundry market. In addition, the method described herein permits the production of detergent products which will, for the first time, permit the home laundry market to utilize harsher chemicals and a wider variety of detergent products than could heretofore be safely commercially sold.

Also, other means could be used to direct gas or air under pressure into the rotating chamber; and in connection with the shaping and treating of certain particles it may not be necessary to periodically, abruptly reduce the rotational speed of the chamber. In some instances, and particularly with a machine similar to that shown in FIGS. 7 and 8, the tumbling of the particles in the chamber may be accomplished by abruptly varying the flow and/or pressure of the gas or air introduced into the chamber. In addition, and as noted above, the size, number and angle of the plenum chambers and fan blades used in the machine 11 may be varied, depending on the particles to be shaped and/or treated and, of course, the cycle of operations can be changed.

Therefore, the preferred embodiments of the invention described herein are to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are thus intended to be embraced therein.

I claim as my invention:

l. A method of shaping particles ofa laundry product such as soap and detergent into compact, generally spherical beads, comprising:

rotating the particles in a rotating chamber having an annular outer wall at a sufficiently high speed so that the centrifugal force exerted on the particles resists the gravitational force sufficiently that the particles are held in a generally annular bed adjacent the outer wall about the rotational axis of the chamber;

fluidizing the particles in said annular bed by continuously introducing gas under pressure into said annular bed to cause the particles to continually strike each other and the walls of the chamber to cause the particles to be compacted and rounded; and intermittently causing a substantial-portion of the fluidized particles to be forced out of said annular bed to cause further striking of the particles with each other and with the walls of the chamber to cause further compacting and rounding of the particles.

2. The method of shaping particles described in claim 1 in which said particles are intermittently forced out of said annular bed by periodically, abruptly reducing the rotational speed of the chamber to an intermediate speed at which the gravitational force overcomes the centrifugal force sufficiently that a substantial portion of the fluidized particles fall away from the outer wall of the rotating chamber and are cast down into a lower portion of the rotating chamber.

3. The method of shaping particles described in claim 2 including the step of returning the rotational speed of the rotating chamber to said initial speed after the step of reducing the rotational speed of the rotating chamber from said initial speed to said intermediate speed, whereby said annular bed of fluidized particles is again formed to continue the compacting and rounding of the particles.

4. The method of shaping particles described in claim 1 including the step of heating the gas introduced into the rotating chamber so as to heat the fluidized particles exposed to the gas in said annular bed; and exhausting the gas introduced into said annular bed from the rotating chamber adjacent to said rotational axis of the chamber.

5. The method described in claim 4 including the step of recirculating at least a portion of the gas exhausted from the rotating chamber back into said annular bed.

6. The method described in claim 1 in which a particle treating fluid is introduced into said annular bed to cause coating of the spherical beads.

7. The method described in claim 6 in which the gas introduced into the rotating chamber is heated to heat the fluidized particles exposed to the gas in said annular bed. 

1. A method of shaping particles of a laundry product such as soap and detergent into compact, generally spherical beads, comprising: rotating the particles in a rotating chamber having an annular outer wall at a sufficiently high speed so that the centrifugal force exerted on the particles resists the gravitational force sufficiently that the particles are held in a generally annular bed adjacent the outer wall about the rotational axis of the chamber; fluidizing the particles in said annular bed by continuously introducing gas under pressure into said annular bed to cause the particles to continually strike each other and the walls of the chamber to cause the particles to be compacted and rounded; and intermittently causing a substantial portion of the fluidized particles to be forced out of said annular bed to cause further striking of the particles with each other and with the walls of the chamber to cause further compacting and rounding of the particles.
 2. The method of shaping particles described in claim 1 in which said particles are intermittently forced out of said annular bed by periodically, abruptly reducing the rotational speed of the chamber to an intermediate speed at which the gravitational force overcomes the centrifugal force sufficiently that a substantial portion of the fluidized particles fall away from the outer wall of the rotating chamber and are cast down into a lower portion of the rotating chamber.
 3. The method of shaping particles described in claim 2 including the step of returning the rotational speed of the rotating chamber to said initial speed after the step of reducing the rotational speed of the rotating chamber from said initial speed to said intermediate speed, whereby said annular bed of fluidized particles is again formed to continue the compacting and rounding of the particles.
 4. The method of shaping particles described in claim 1 including the step of heating the gas introduced into the rotating chamber so as to heat the fluidized particles exposed to the gas in said annular bed; and exhausting the gas introduced into said annular bed from the rotating chamber adjacent to said rotational axis of the chamber.
 5. The method described in claim 4 including the step of recirculating at least a portion of the gas exhausted from the rotating chamber back into said annular bed.
 6. The method described in claim 1 in which a particle treating fluid is introduced into said annular bed to cause coating of the spherical beads.
 7. The method described in claim 6 in which the gas introduced into the rotating chamber is heated to heat the fluidized particles exposed to the gas in said annular bed. 